Swisscube

Physical and Launch Requirements

1. Mass Limits

o Total satellite mass: ≤1 kg

o Structural subsystem target: 202g (including primary structure, secondary

structure, deployment switches, and separation springs)

o Center of mass must be within 2cm of geometric center

2. Material Specifications

o Primary recommendation: Aluminum 7075-T73 (P-PPOD material) or 6061-T6

o Alternative materials must have similar CTE to P-POD material (Al-7075-T73)

o Composite materials allowed but must avoid micro-buckling of fibers

3. Structural Performance

o Must withstand 10g launch accelerations (7.5g actual with 1.25 safety factor)

o No yielding, excessive deformation, or buckling allowed. Local buckling can be

tolerated only if reversible. The structure shall be designed to meet the
requirements for stiffness under the specified load and boundary conditions

o Natural frequency requirements:

1. 20–45 Hz for longitudinal axis

2. 15 Hz for lateral axis

4. Launch Environment

 SwissCube is designed to minimize jamming in the PPOD, cause minimum

danger to neighbouring CubeSats and all parts should remain attached to the
CubeSat during launch, ejection and operation
 No electronics must be active during launch
 Use NASA provided materials wherever possible
 Deployables should be constrained by CubeSat and not the PPOD. PPOD is
solely used for ejection of the CubeSat and not a structural member
 RBF pins are removed once the CubeSats are placed inside the P POD. RBF
pins must fit within the designated data ports, should not protrude out more
than 6.5mm when fully inserted
  One deployment switch is required, 2 are recommended
 Rails must be smooth and edges must be rounded to a minimum radius of 1
mm.
 At least 75% (85.125 mm of a possible 113.5mm) of the rail must be in
contact with the P POD rails
 All rails must be hard anodized to prevent cold-welding, reduce wear, and
provide electrical isolation between the CubeSats and the P-POD.
 Separation springs must be included at designated contact points

5. Testing & space requirements

 Random vibration testing at a level higher than the published launch vehicle
envelope outlined in the MTP.
 Thermal vacuum bakeout to ensure proper outgassing
 For controlled environment: temp range from -40 to 70 C
 For non controlled environment: temp range from -150 to 150 C
 Thermal vacuum testing has to be performed at a minimum vacuum level of 5
x 10-4 Torr and at a temperature of 70°C

6. Launch Vehicle Constraints

In the computation of safety margins the following minimum factors of safety shall be used
for standard metallic materials:

• yield stress factor of safety 1,25

• ultimate stress factor of safety 1,5

• minimum fatigue factor (cycles) 4

7. Principles used for Design

o A construction with stacked frames is very simple as most of the parts are
identical. The drawbacks are high mass, due to the fact that the frames must be
interconnected, and low maintainability, as the body is not easily disassembled
after attachment of, for example. the solar cells.
 o A box and lid construction combined with a motherboard type electronic
backbone makes the maintenance of the electronic circuits easy, as they can be
slid freely in and out of the structure. Here the drawback is the difficulty of
assembly of the systems accommodated in the box, as they must be installed
inside the small cavity, and are not easily disassembled again.

Principle of Fewest Possible Parts:

Every joint in a structure requires fasteners and is most likely making the construction
both weaker and heavier. To avoid this, a design featuring as few joints as possible might
be developed.

Advantages:

Better Tolerance Control: Using a single-piece machined structure (instead of assembling

multiple parts) minimizes errors in alignment and fit.

Improved Thermal Conductivity: A solid metal body transfers heat more efficiently,
helping with temperature regulation in space.

Disadvantages:

Manufacturing Challenges: Machining complex internal shapes within the small CubeSat
body is extremely difficult and requires careful planning.

Low Design Flexibility: Since not all CubeSat subsystems are finalized, a one-piece
structure makes late-stage modifications harder.

Principle of Maximum Flexibility:

If the satellite body is built from multiple smaller pieces (like an IKEA kit), each part can
be designed for a specific function, maximizing design flexibility.

Advantages:

Easier Modifications: If a subsystem changes, only the affected parts need to be

redesigned, while the rest of the structure remains unchanged.
Simpler Manufacturing: Individual components have less complex geometries, making
them easier to produce.

Disadvantages:

Weaker Thermal & Electrical Properties: Multiple parts create thermal and electrical
discontinuities, reducing heat dissipation and conductivity.
Complex Assembly: Requires precise alignment and a detailed assembly plan to ensure
everything fits correctly.
 Increased Weight & Vibrational Issues: More fasteners and joints mean a heavier
structure and potential weaknesses under launch vibrations.

8. Assumptions
o In the initial design phase, mechanical loads and vibration spectra imposed on
the satellite are not clearly defined, since neither the orientation of P-POD in
the launch vehicle, nor the position of the SwissCube in the P-POD are
defined, so worst case assumptions are made.

o Maximum Launch Acceleration:

Axial: 7.5g (DNEPR case)

Lateral: Significantly lower

o Worst-Case Positioning:

If SwissCube is at the lowest position in a vertically oriented P-POD, it must

support the weight of all CubeSats stacked above it.

o Factor of Safety (FoS):

To account for uncertainties in load distribution, yield stress FoS of 1.25 is

applied.

This increases the design acceleration from 7.5g to 9.375g, rounded to 10g
for design calculations

o From the different possibilities for the payload, preliminary design trades
where established considering a cylindrical camera with a lens diameter of
25mm.

9. Material Trades

The criteria for selection were based on characteristics listed below: -

Strength

Weight

Coefficient of thermal expansion

Machineability

Cost

CubeSat Material Requirements for SwissCube

1. Thermal Expansion Compatibility

- The CubeSat standard requires materials with a similar thermal expansion coefficient
(CTE) to the P-POD deployer.

- The P-POD is made of Aluminum 7075-T73 (CTE: 23.6 µm/m·°C).

- Recommended alternatives:

- Al-7075-T73 (same as P-POD)

- Al-6061-T6(similar CTE, slightly lower strength)

2. Weight Reduction Strategy

- Composite materials (e.g., carbon fiber) were considered for non-critical panels due to
their lower density

3. Rail Material Decision

- Rails must be aluminum (likely Al-7075-T73) to ensure:

- Perfect CTE match with the P-POD.

- Structural reliability during launch (failure could destroy the satellite or block others in
the P-POD).

- No composites were considered for rails due to risk of misalignment or deformation

under launch loads.

Materials

Aluminum (Primary Structural Material)

Widely Used in Spacecraft: Aluminum alloys are the go-to material for both primary and
secondary structures.
Best Conductivity-to-Weight Ratio: It provides excellent thermal and electrical conductivity
while keeping mass low.
Ideal Thermal Expansion: Its thermal expansion coefficient matches well with satellite
applications, preventing material stress from temperature fluctuations.

Other Metals (Not Suitable for Main Structure)

Steel & Titanium: Too dense, making them unsuitable due to the satellite’s strict weight
limitations.
Magnesium & Beryllium: Although lightweight, they are expensive and difficult to machine,
making them impractical.

Composites

1. Types of Composites Considered

Fiber-Reinforced Polymer Composites:

 Includes prepegs and honeycomb-core sandwich panels.

 Honeycomb panels are lighter, more rigid, and have better impact resistance than
prepegs.

 Used in electronic circuit board substrates.

Common Fiber Types:

 Carbon Fiber → Conductive, lightweight, strong.

 Aramid Fiber (Kevlar) → Non-conductive, lightweight.

 Glass, Boron, Metallic Fibers are also options but less commonly used.

Polymer Matrices (Binding Resins):

 Epoxy & Cyanate Esters (thermosetting resins) are the most stable for space
applications.

 Cyanate Esters are preferred over epoxies due to lower water absorption, despite
being more expensive.

2. Advantages of Composites

🔹 Extremely lightweight thus helps meet mass constraints.

🔹 Honeycomb panels provide good rigidity and impact resistance.
🔹 Thermosetting plastics are stable in space (if ECSS standards are followed).

3. Disadvantages of Composites

Poor choice for main structure due to:

 Low thermal and electrical conductivity.

 Different expansion rates in fiber layers can cause micro-cracking under thermal
cycling.

 Water absorption and outgassing → Can lead to contamination of nearby

components.
Difficult to test before use thus water absorption and outgassing properties often rely on
supplier data rather than direct testing.

[Link] methods

Structural adhesives

o Adhesives are the most lightweight method for joining different mechanical
parts.
o most lightweight method for joining different mechanical parts and only
create a weak stress concentration at the interface
o can be used to join different kinds of materials providing stress relief through
deformation for materials with different thermal expansion coefficients
o disassembly is generally impossible once parts are attached
o adhesives that are subject to thermal cycling may degrade and thus become
brittle
o provide a weak thermal and electrical conductivity thus problematic for
joining parts where heat dissipation is required
o silicones are prohibited for space use since contamination is risked in vacuum
conditions

Mechanical fasteners (screws, rivets…)

o parts can be disassembled and reassembled numerous times during the testing
phase.
o risk of stress concentration whereas for adhesives the stress is evenly distributed.
o environmentally stable except for minor risks of corrosion during long term use
o during final assembly screws have to be glued in order to prevent the risk of
disassembly during launch due to vibrations.

Welding

o least expensive joining method

o provides mechanically strong interfaces
o disassembly of welded parts is impossible and welding is only applicable for joining
of metallic surfaces
o formation of fragile intermetallics and increasing the risk of selective and
intergranulary corrosion
o welding of aluminum is an extremely difficult procedure due to its weak melting
temperature
o welding will probably not find an application for joining SwissCube structural
components
[Link]-offs for Primary Structure Design Concepts

Monoblock

o frame of aluminum which is milled from one solid block of aluminum

o very strong, robust and at the same time extremely light frame
o assembly consists of fixing components to the frame, directly on the internal face of
the various sides of the frame. The subsystems for the satellite should be
inserted/removed in a certain order
o advantages of this option are a reduction in the tolerance stack-up, the optimal
thermal and electrical conductivity, and the saved mass because no joints are
required between the various parts of the frame
o manufacturing problem, the accessibility of the subsystems, or the low flexibility,
making design changes difficult

Double Monoblock

o modular and serviceable

o triangular structure allows for easy disassembly
o can be split into two symmetrical halves by removing 8 screws and allows access to
all important subsystems
o two halves are actually composed of low profile triangular pieces and four cross
members making it cost effective
o assembly consists of sliding components into place and using fasteners to secure
them
o advantage of this solution are easy serviceability of the interior components, efficient
mounting of electronics and payload, or the fact that diagonal cross members offer
more structural rigidity.
o disadvantage is the redundancy of the diagonal crossbars, due to their additional
weight

Structure in Panels

o two principal panels consist of two rails each and the other panels come to be fixed
from above.
o advantages of this strategy are the flexibility and simplicity to reach the other
subsystems
o mass of the main structure is very high, because of the thickness of the structure
panels
o external geometrical tolerances are difficult to reach because of the assembly of
several parts and the risk of non-alignment

IKEA Kit
 o four rails, eight cross-bars and 16 L-sections, allowing the crossbar to be
connected to rails and also provide surfaces for the mounting of faceplates
o all pieces can be fabricated from commonly available extruded sections; they do
not require expensive machining
o simple design thus short design time
o main disadvantage is that the external geometrical tolerances are difficult to
reach; the mass of the frame is passably raised, because there are a lot of
interfaces and thus many screws

Placement of the Payload

The payload (a cylindrical camera, ~30 mm diameter × 70 mm length) is the largest single
component, influencing the satellite’s COM and structural design. Three placement options
were evaluated:

1. Parallel to P-POD Rails (Z-axis):

o Pros: Simplifies integration with deployer.

o Cons: Limits space for other subsystems and risks misalignment during launch
vibrations.

2. Perpendicular to Rails (X/Y-axis):

o Pros: Frees space along the rail axis for PCBs and antennas.

o Cons: Requires cantilevered support, increasing stress on the frame.

3. Offset from Geometric Center:

o Pros: Balances CoM when combined with other subsystems.

o Cons: Requires careful mass distribution to keep CoM within 2 cm of the

cube’s center.

Final Choice: The payload was placed perpendicular to the rails (Y-axis), protruding from one
face, with an offset to optimize CoM. This allowed five faces to remain free for solar panels
and antennas.

Arrangement of the Main PCBs

Five to six PCBs (e.g., ADCS, EPS, COM) needed efficient placement. Three configurations
were compared:

1. Stacked Layers (Vertical):

o Pros: Compact, rigid, and easy to secure.

 o Cons: Limited access to inner boards and complex interconnections.

2. Mounted on Internal Faces:

o Pros: Direct thermal paths to aluminum frame.

o Cons: Wiring complexity and restricted space for payload.

3. Slot-Mounted with Motherboard:

o Pros: Centralized connections (reduced wiring), modularity, and easier

maintenance.

o Cons: Requires precise alignment and adds motherboard mass.

Magnetic Torquers and Inertial Wheel

o The coils should be as large as possible to maximize efficiency.

o They must be coplanar with the spacecraft's external faces for a practical design.
o Magnetic torquers & inertial wheels:
Number: Can range from one to three (or more for redundancy)
Limiting factors: Mass and available space within the CubeSat
o ADCS components can be internally or externally mounted depending on space
constraints and mission requirements.

Antenna Array

Fixing Location Options:

 External mounting (most common).

 Internal deployment system (possible but more complex).

Antenna Orientation Choices:

 In-plane with the mounting surface (simpler).

 Perpendicular to the mounting surface (more challenging to implement).

Batteries

Battery Specifications:

 Rectangular shape: 35 × 70 × 5 mm (TBC).

 Two batteries used in the satellite.

Thermal Constraints:
  Must be kept within 0°C to 45°C (TBC).

 Special insulation may be required based on thermal conditions.

Placement Considerations:

 Not structurally critical but can be optimized for mass balance.

Baseline Design:

Main Frame

Mass Optimization:

 The frame design was meticulously refined to minimize mass while complying with
CalPoly restrictions.

 Final frame mass: 99 g.

Structural Modifications:

 Mass-saving features:

o 6 mm diameter holes and 2 mm chamfers (at 45°) in each rail.

 Crossbars:

o Rectangular section (3 × 4 mm).

o X-axis crossbars have protuberances for securing internal subsystems and

external panels.

o Y-axis crossbars are reinforced for structural rigidity.

Payload Support Considerations:

 The Y-side frame has additional structural elements to support the payload.

 Since the payload is cantilevered, extra crossbars ensure its alignment remains
stable.

Spacers

Functionality:

 Connects PCBs to each other and secures the stack to the main frame.

 Acts as a thermal path between PCBs and the aluminum frame.

Material & Design:

 Made from Certal aluminum alloy (Appendix B - Material Properties).

  Three-part structure, each screwed together to form a complete spacer.

 External diameter: 6 mm, Internal diameter: 4 mm.

 Threaded holes at the ends for frame attachment.

Size & Mass:

 Total length of a spacer unit: 24.5 mm.

 Each spacer weighs: 2 g.

 Total spacers used: 8 in the structural subsystem.

Sides & Top Panels

Faceplate: Provides surface for mounting external components (solar cells, magnetic
torquers, etc.).

Side Panels:

 Rectangular composite plates (83mm wide x 100mm long, 1mm thick).

 Elevated 2mm center section for winding magnetic torquers.

 Three side panels used, each weighing 13g.

 Possible mass reduction by adding holes (no significant stress on solar cells or
panels).

Top and Bottom Plates:

 100mm x 100mm with corner cut-outs.

 Fabricated from 1mm thick composite material.

 Elevated center section like side panels.

 Each weighs 13g.

 Two top plates used in the structural subsystem

Payload Panel

Purpose: Mounts antennas and includes holes for payload and access port.

Holes:

 Payload hole: 25mm diameter (TBC).

 Access port: Size depends on the type and dimensions of the connections (TBC).

Dimensions: 83mm wide x 100mm long, 1mm thick (TBC).

Material: Likely composite, depending on antenna deployment system attachment.

Mass: 13g.

Usage: One panel of this type used in the structural subsystem.

Material Choices

Main Frame Material: Aluminum alloy used to match thermal expansion coefficient of P-
POD material (Aluminum alloy Al–7075–T73).

 Chosen Alloy: Certal® (Al-7022-T651), similar to Al–7075–T73.

 Reason for choice: Similar properties to Al-7075; CubeSat doesn’t need special
corrosion protection.

 Not ECCS Standards-recommended, but deemed suitable.

Payload Structure Material: Titanium.

 Chosen for similar thermal expansion coefficient to glass (used in optics).

 Titanium’s high strength will protect optics.

 Specific titanium alloy not yet defined.

Assembly Process:

 Panels and reaction wheel attached first

 Internal PCBs and payload connected via motherboard

 Connections made through motherboard or openings on Z- or Y-planes for loose

wires.

 Remaining side panels attached and connected

 Solar cells and magnetic torquers pre-mounted on panels.

External Panels Material: Likely carbon fiber composite in epoxy resin matrix.

 Alternative: Honeycomb structure between carbon panels.

 Further research needed for these options.

 Potential concern: Whether payload panel (with optics) can support antenna
deployment system.

 Decision pending: Dynamic analysis of panel deformations and thermal subsystem

feedback.

Advantages of Carbon Fiber Composite Panels:

 Lower density than aluminum (40-50%).

 Better electromagnetic insulation (important for magnetic torquers).

  Thermal expansion coefficient between solar cells and main aluminum frame.

Disadvantages of Carbon Fiber Composite Panels:

 Lower thermal conductivity than aluminum.

 Lower radiation absorption capacity compared to aluminum.

 Possible solution: Adding aluminum foil or another conductive metal to interior and
exterior faces of panels

Fastening Preferences

o Main Frame and Crossbars: Screws will be used for fastening due to the ability to
disassemble and reassemble parts.
o Final Assembly: Screws will be glued to prevent disassembly during launch due to
vibrations.
o Exterior Panels: Adhesives preferred as they reduce stress concentration and can
bond different materials (e.g., carbon fiber composites and aluminum).

Adhesive Types:

o Common options: Two-component epoxy pastes or adhesive films.

o Epoxy pastes are preferred due to small surface areas needing bonding.
o Structural adhesives and thermal adhesives are listed in Appendix C - Adhesive
Properties.
o Adhesives are space-qualified (low outgassing coefficients).

Adhesive Selection Criteria:

o Thermal Properties: Adhesives must support optimal heat transfer and be applicable
in the temperature range defined by the thermal subsystem.
o Cure Temperature: Ideally low to avoid affecting electronic components. Target cure
temperature is 80°C (compatible with thermal vacuum testing).
o Physical Properties: Adhesives should have high shear strength to withstand stresses
caused by CTE mismatch between aluminum frame and composite plates.

Physical and Inertial properties of Baseline

o SwissCube is within the 1 kg limit with a margin of 87 g

 o C.o.M. must be in 20 mm
o payload must have a inclination between 17 and 27 degree

Worst Case Load

For the worst case we shall consider the P-POD in a direction parallel to the direction of
maximum acceleration during launch. As the deployment system holds three CubeSats the
worst case will be experienced by the CubeSat on the bottom. During the launch sequence
this CubeSat must maintain structural integrity while supporting not only its own weight but
the weight of the two overlying picosatellites. Using the CubeSat design specifications the
following assumptions can be made regarding the worst case static load of the SwissCube:

• The maximum acceleration will be equivalent to 7.5 g (Dnepr maximum acceleration)

• The mass of each of the three satellites is equal to 1kg With a factor of safety of 1.25, the
acceleration is 9.375 g, so it can be rounded to 10 g

The SwissCube will need to be able to tolerate a loading equivalent to an axial force of
196.2N with an acceleration of 10 g. This will be known as the worst case axial loading
condition

for P-POD aligned in a direction perpendicular to the direction of maximum acceleration, all
three satellites will experience the same loading condition irrelevant of their location with in
the P-POD; assuming that the P-POD does not transfer any forces into the CubeSats. Then
the CubeSats will only be required to support their self weight in a 10 g. gravity field. This
will be known as the worst case lateral loading condition

Testing

o To meet CubeSat standards, the completed SwissCube engineering model

must undergo both vibration and thermal vacuum tests.

 Test Pod:

o Purpose: Simulates the P-Pod deployer environment for validating the

structural integrity of CubeSats under launch conditions.

o Environment Simulation: Designed to replicate the conditions inside the P-

Pod deployer, enabling developers to test satellites without needing to
simulate full launch vehicle loads.

 Vibration Testing:

o Conducted at California Polytechnic with the following tests:

 Sine Sweep Test:

 Frequency range: 50-2000 Hz.

  Duration: 3 minutes.

 Sweep mode: Logarithmic.

 Maximum test level: 10 Grms

 Random Vibration Test:

 Duration: 60 seconds.

 Maximum test level: 10 Grms

 Additional individual structural part vibration tests will be performed

with a shaker to identify vibration modes.

 Thermal Vacuum Test:

o Conditions: High vacuum (5x10^-5 torr) and temperature range from -20°C to
60°C.

o Cycle Duration: 6 hours (1 hour soak at each temperature extreme, 30

minutes for temperature ramping).

o Temperature Range Variation: Subject to payload requirements.

 Structural Subsystem Tests:

o Vibration Testing: Includes tests for individual structural parts.

o Interface Testing (Adhesives):

 Focus on the epoxy adhesive’s performance, particularly its resistance

to thermal cycling and CTE differences.

 Includes thermal cycling to check fatigue performance of the bond.

o Solar Cell Mechanical Testing:

 Tests to determine bending resistance and the maximum allowable

bending or vibration amplitude during launch to protect the solar
cells.